Cashco CA-2 User Manual

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INSTALLATION, OPERATION & MAINTENANCE MANUAL

MODELS CA-1 AND CA-2

BACK PRESSURE / RELIEF REGULATORS

SECTION I

DESCRIPTION AND SCOPE

Models CA-1 and CA-2 are back pressure/relief regulators used to control upstream (inlet or P1) pressure. Sizes for CA-1 – 1/8" and 1/4" (DN6 and DN8); for CA-2 – 3/8" and 1/2" (DN10 and DN15). Both models are bronze bodied units. With proper trim utili za tion, both units are suitable for liquid and gaseous service. Refer to Tech ni cal Bul le tin CA-TB for speciﬁ c design conditions and selection rec om men da tions.

The instructions in this manual will refer to both models, unless otherwise stated.

CAUTION A

This is not a safety device and must not be sub sti tut ed for a code approved pressure safety relief valve or rupture disc.

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SECTION II

II. INSTALLATION

1. An inlet block valve should always be in stalled.

2. If service application is continuous such that shut down is not readily accomplished, it is recommended that an inlet block valve, outlet block valve, and a manual bypass valve be installed.

3. Pipe unions should be installed to allow removal from piping.

4. An inlet pressure gauge should be located ap proxi mately ten pipe diameters upstream, and within sight. An outlet pressure gauge is op tion al.

5. All installations should include an upstream safe ty relief de vice if the inlet pressure could ex ceed the pres sure rating of any equip ment or the max i mum inlet pres sure rating of the unit.

Recommended Piping Schematic For Back Pressure/Relief Station

6. Clean piping of all foreign material including chips, welding scale, oil, grease and dirt before installing the regulator. Strainers are rec om mend ed.

The maximum inlet pressure is equal to 1.5 times the larger number of the stated range spring on the name plate, and is the rec om mend ed "upper op er a tive limit" for the sens ing diaphragm. Higher press ures could dam age the di a phragm. (Field hydro static tests fre quent ly destroy dia phragms. DO NOT HYDRO STATIC TEST THRU AN IN STALLED UNIT; ISO LATE FROM TEST.)

WARNING 1

7. In placing thread sealant on pipe ends prior to en gage ment, ensure that excess material is re moved and not allowed to enter regulator upon startup.

8. Flow Direction: Install so the flow di rec tion aligns with the word “IN” stamped on the body. Con nect the inlet pres sure to the body (1) side

Models CA-1/CA-2 BP/Relief Regulator Flow-Thru Design

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connection(s). Fluid will relieve out the bottom con nec tion for Angle or Flow-Thru design and out the other side con nec tion for Globe design (side inlet-side out let).

9. Regulator may be installed in a vertical or hor i zon tal pipe.

10a. Basic Regulator - (Refer to Figure 1): Regulator

may be rotated around the pipe axis 360°. Rec om mend ed position is with spring chamber ver ti cal

SECTION III

downwards. Orient such that the spring cham ber (2) vent hole does not collect rainwater.

10b. Cryogenic Regulator, Opt-5 – Recommended in -

stal la tion is in horizontal line with spring chamber (2) oriented downwards below the body (1).

11. Regulators are not to be direct buried un der ground.

12. For insulated piping systems, the rec om men da tion is to not insulate the regulator.

III. PRINCIPLE OF OPERATION

1. Movement occurs as pressure variations register on the diaphragm (11). The registering pressure is the inlet, P

, or upstream pressure. The range

spring (6) opposes diaphragm (11) movement. As inlet pressure drops, the range spring (6) pushes

IV. START-UP

1. Start with the block valves closed. A bypass valve may be used to maintain inlet pressure in the up stream system without changing the fol low ing steps.

2. Relax the range spring (6) by turning the adjusting screw (3) counter clockwise (CCW) a minimum of three (3) full revolutions. This reduces the inlet (up stream) pres sure setpoint.

3. If it is a “hot” piping system, and equipped with a bypass valve, slowly open the bypass valve to pre-heat the system piping and to allow slow ex pan sion of the piping. Closely monitor inlet (up stream) pres sure via gauge to assure not over-pressurizing. NOTE: If no bypass valve is

in stalled, extra caution should be used in starting up a cold system; i.e. do everything slowly.

the diaphragm (11) down, closing the port; as inlet pres sure in creas es, the diaphragm (11) push es up and the port opens.

2. A complete diaphragm (11) failure will cause the reg u la tor to fail closed.

SECTION IV

7. Observing the inlet (upstream) pressure gauge, simultaneously ro tate the adjusting screw (3) clock wise (CW) slowly and begin to close the bypass valve, if installed, until the inlet pres sure be gins to rise. Ro tate adjusting screw (3) CW until the de sired set point is reached.

8. Continue to slowly open the inlet (upstream block valve. If the inlet (upstream) pressure exceeds the desired setpoint pressure, rotate the ad just ing screw (3) CCW until the pres sure decreases.

9. When ﬂ ow is established steady enough that both the outlet and inlet block valves are fully open, ensure that the bypass valve is closed, if in stalled.

10. Develop system ﬂ ow to a level near its expected normal rate, and reset the regulator setpoint by turn ing the ad just ing screw (3) CW to increase inlet pressure, or CCW to reduce inlet pressure.

4. Crack open the inlet (upstream) block valve.

5. Slowly open the outlet (downstream) block valve ob serv ing the inlet (upstream) pressure gauge. De ter mine if the regulator is ﬂ owing. If not, slowly rotate the regulator adjusting screw (3) clockwise (CW - viewed from spring chamber (2) top) until ﬂ ow begins.

6. Continue to slowly open the outlet (downstream) block valve until fully open.

11. Reduce system ﬂ ow to a minimum level and ob - serve setpoint. Inlet pressure will rise from the setpoint of Step 9. (Assure that this rise does not exceed the stated upper limit of the range spring (6) by greater than 50% i.e. 40-90 psig (2.8 - 6.2 Barg) range spring (6), at maximum ﬂ ow the inlet pressure should not exceed 1.5 x 90 psig (6.2 Barg), or 135 psig (9.3 Barg). If it does, consult factory).

12. Increase ﬂ ow to maximum lev el, if possible. Inlet (up stream or P

) pressure should fall off. Re ad just

setpoint as necessary at the normal ﬂ ow rate.

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SECTION V

V. SHUTDOWN

1. On systems with a bypass valve, and where sys tem pressure is to be maintained as the reg u la tor is shut down, slowly open the by pass valve while closing the inlet (up stream) block valve. Fully close the inlet (upstream) block valve. (When on bypass, the sys tem pressure must be constantly ob served and man u al ly regulated. Close the outlet (down stream) block valve.

VI. MAINTENANCE

WARNING 2

SYSTEM UN DER PRES SURE. Prior to performing any maintenance, isolate the reg u la tor from the system and relieve all pres sure. Failure to do so could result in personal injury.

A. General:

1. Maintenance procedures hereinafter are based upon removal of the regulator unit from the pipe line where installed.

CAUTION B

Do not walk away and leave a bypassed reg u la tor unattended.

2. If the regulator and system are to both be shut down, slowly close the inlet (upstream)

block valve. Close the outlet (downstream) valve only if reg u la tor re mov al is required.

SECTION VI

2. Relax range spring (6) by loosening the lock nut (4) and turning ad just ing screw (3) CCW until re moved from spring cham ber (2).

NOTE: If the Option -2 handwheel is utilized, the ad just ing screw (3) and lock nut (4) are replaced with a knob (18) and lock nut (4). With the Option-22 panel mounting w/handwheel, the ad just ing screw (3) and lock nut (4) are replaced with a knob (18), lock nut (4) and a panel mounting nut (19).

3. Loosen spring chamber (2) by placing wrench on “ﬂ ats” and rotating CCW.

4. Remove spring chamber (2), spring button (5) range spring (6), and diaphragm stop (9).

2. Owner should refer to owner's procedures for removal, handling, cleaning and disposal of non reuseable parts, i.e. gaskets, etc.

3. Refer to Figure 1, Model CA-1 or CA-2 for the basic regulator. Blow-ups of options are in clud ed with each drawing.

B. Diaphragm Replacement

CAUTION C

To prevent damage to body, use lead jaws when placing body in a vise. Position so that vise closes over inlet and outlet of the body.

1. Securely install the body (1) in a vise with the spring chamber (2) directed upwards.

WARNING 3

SPRING UNDER COMPRESSION. Prior to re mov ing spring chamber, relieve spring compression by back ing out the ad just ing screw. Failure to do so may result in ﬂ ying parts that could cause personal injury.

5. Remove the diaphragm subassembly con sist ing of the pressure plate nut (7), lock wash er (8), pressure plate (10), diaphragm (11), plug gasket (13) and plug (14). NOTE: Refer to the quan tity of dia phragms (11) in cor po rated per

the bill of ma te ri als listing. De pend ing on inlet pressure level, multiple metal diaph ragms (11) may be “stacked”.

Model's CA-1/CA-2 Diaphragm Sub as sem bly

6. Loosen pressure plate nut (7) and sep a rate all parts (7, 8, 10, 11, 13 & 14) of the di a phragm sub as sem bly.

7. Inspect pressure plate (10) to ensure no de for ma tion due to over-pressurization. If de formed, re place.

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8. Remove diaphragm gasket (12) for metal dia-

phragm (11). NOTE: No diaphragm gas ket

(12) for composition diaphragm (11).

9. Clean body (1) and di a phragm ﬂ ange. NOTE:

On reg u la tors origi nally sup plied as “oxygen clean”, Option -5 or Option -55, main tenance must in clude a level of clean li ness equal to Cash co's clean ing stan dard #S-1134. Con tact fac to ry for de tails.

15. Reinstall ad just ing screw (3) with locknut (4) into the spring chamber (2).

16. Pressurize with air and spray liquid leak de tec tor to inspect entire body (1) and spring cham ber (2) for leakage. En sure that an inlet pres sure is main tained dur ing this leak test of at least mid-range spring level; i.e. 40-90 psig (2.8-6.2 Barg) range spring, 65 psig (4.5 Barg) test pres sure min i mum.

10. Reassemble diaphragm subassembly by plac ing plug gasket (13), diaphragm(s) (11), pres sure plate (10) and lock washer (8) over thread ed post of plug (14). En sure the pres sure plate (10) is placed with curved outer rim down next to the di a phragm (11) surface.

CAUTION D

Use only gaskets supplied by Cashco, Inc. for these products.

Place a thread seal ant com pound similar to Loctite #271 on the threads of the plug's (14) post prior to tightening the pressure plate nut (7) to the fol low ing torque values:

Composition 15 In-lbs. 1.7 N-m

Sizes Diaphragm Torque

Metal 60 In-lbs. 6.8 N-m

ALL

11. Place diaphragm gasket (12) on body (1), then in sert the di a phragm sub as sem bly into the body (1).

12. Place diaphragm stop (9) and range spring (6) over the pres sure plate nut (7) of the di a phragm sub as sem bly.

C. Trim Replacement

1. Trim inspection requires the diaphragm sub as sem bly be removed. Refer to previous pro ce dure, Sec tion VI.B.

2. Inspect inside surface of seat ring (15) and seating surface of plug (14). If seating surface shows signs of erosion/wear, the seat ring (15) and plug (14) should be replaced.

3. Clean body (1) cavity. Clean all parts to be reused. NOTE: On regulators originally sup-

plied as “oxygen clean”, Option -5 or Option

-55, main te nance must include a lev el of clean li ness equal to Cashco's clean ing stan dard #S-1134. Contact factory for de tails.

4. Inspect the surface in the body (1) cavity where seat ring (15) rests. If surface area of either mating part shows signs of erosion/ wear, re place with new regulator.

5. Place seat ring (15) in center of body (1) cavity. Ensure that the shoulder on outer edge of seat ring (15) faces up towards the di a phragm (11).

13. Place multi-purpose, high temperature grease into de pres sion of spring button (5) where ad just ing screw (3) bears. Set spring but ton (5) onto range spring (6); en sure spring button (5) is laying ﬂ at.

14. Rotate the spring chamber (2) CW by hand into the threaded portion of the body (1) as sur ing not to cross thread. Continue hand ro tat ing CW until ﬁ rmly seated against the di a phragm stop (9). Wrench tight en se cure ly to the following torque values:

Model Torque

CA-1 20-25 Ft-lbs. 27-34 N-m CA-2 25-30 Ft-lbs. 34-40 N-m

6. Reinstall diaphragm subassembly per Sec tion VI.B., Diaphragm Replacement.

7. Bench test unit for suitable operation. NOTE:

Reg u la tors are not tight shut off devices. Even if pressure falls below setpoint, a reg u la tor may or may not develop bubble tight shut off. In general, tighter shut off can be

ex pect ed with composition seat.

8. Pressurize with air and spray liquid leak de tec tor to inspect entire body (1) and spring cham ber (2) for leakage. Test pressure should be the max i mum allowed by the range spring at the inlet.

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VII. TROUBLE SHOOTING GUIDE

1. Erratic operation; chattering.

SECTION VII

Possible Causes

Remedies

A. Oversized regulator. A1. Check actual ﬂ ow conditions, re-size regulator for minimum and maximum ﬂ ow. A2. Increase ﬂ ow rate. A3. Decrease regulator pressure drop; decrease inlet pressure by placing a throttling oriﬁ ce in inlet piping union. A4. Install next step higher range spring. Contact factory. A5. Before replacing regulator, contact factory. B. Worn plug. B. Replace regulator.

2. Regulator inlet (upstream) too high:

Possible Causes

Remedies

A. Regulator undersized. A1. Conﬁ rm by opening bypass valve together with regulator. A2. Check actual ﬂ ow conditions, re-size regulator; if regulator has inadequate capacity, replace with larger unit. B. Incorrect range spring (screwing in CW B. Replace range spring with proper lower range. Contact factory of adjusting screw does not allow bringing pressure level up to proper level. C. Too much rise (build). C1. Review rise (build) expected. C2. Contact factory.

3. Leakage through the spring chamber vent hole.

Possible Causes

Remedies

A. Normal-life diaphragm failure. A. Replace diaphragm. B. Abnormal short-life diaphragm failure. B1. Can be caused by excessive chattering. See No. 1. to remedy chatter. B2. Can be caused by corrosive action. Consider alternate diaphragm material. B3. For composition diaphragms, assure not subjecting to over-temperature conditions. B4. Upstream (inlet) pressure build-up occurring that overstresses diaphragms. Re lo cate regulator or protect with safety relief valve.

4. Sluggish operation.

Possible Causes

A. Plugged spring chamber vent. A. Clean vent opening.

Remedies

B. Fluid too viscous. B. Heat ﬂ uid. Contact factory.

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SECTION VIII

VIII. ORDERING INFORMATION NEW REPLACEMENT UNIT vs PARTS "KIT" FOR FIELD REPAIR

To obtain a quotation or place an order, please retrieve the Serial Number and Product Code that was stamped on the metal name plate and attached to the unit. This information can also be found on the Bill of Material ("BOM"),a parts list that was provided when unit was originally shipped. (Serial Number typically 6 digits). Product Code typical format as follows: (last digit is alpha character that reﬂ ects revision level for the product).

–

NEW REPLACEMENT UNIT:

Contact your local Cashco, Inc., Sales Rep re sen ta tive with the Serial Number and Product code. With this information they can provide a quotation for a new unit including a complete description, price and availability.

CAUTION

Do not attempt to alter the original construction of any unit without assistance and approval from the factory. All purposed changes will require a new name plate with appropriate ratings and new product code to accommodate the recommended part(s) changes.

PARTS "KIT" for FIELD REPAIR:

Contact your local Cashco, Inc., Sales Rep re sen ta tive with the Serial Number and Product code. Identify the parts and the quantity required to repair the unit from the "BOM" sheet that was provided when unit was originally shipped.

–

NOTE: Those part numbers that have a quantity indicated

under "Spare Parts" in column "A” reﬂ ect minimum parts required for inspection and rebuild, - "Soft Goods Kit". Those in column “B” include minimum trim replacement parts needed plus those "Soft Goods" parts from column "A".

If the "BOM" is not available, refer to the crosssectional drawings included in this manual for part identiﬁ cation and selection.

A Local Sales Representative will provide quotation for appropriate Kit Number, Price and Availability.

The contents of this publication are presented for informational purposes only, and while every effort has been made to ensure their accuracy, they are not to be construed as warranties or guarantees, express or implied, regarding the products or services described herein or their use or applicability. We reserve the right to modify or improve the designs or speciﬁ cations of such product at any time without notice. Cashco, Inc. does not assume responsibility for the selection, use or maintenance of any product. Responsibility for proper selection, use and maintenance of any Cashco, Inc. product remains solely with the purchaser.

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MODEL CA-1

Figure 1:

Basic Model CA-1 with

3-Connection Flow-Thru Body

Option-2 Handwheel

Option-5 Cryogenic Construction

Installed in horizontal line with spring chamber ori ent ed downwards below the body. Body and spring chamber Item Num bers are iden ti cal to Figure 1.

I Repair Parts

Item No. Description Kit B

1 Body 2 Spring Chamber 3 Adjusting Screw 4 Lock Nut 5 Spring Button 6 Range Spring 7 Pressure Plate Nut 8 Lock Washer 9 Diaphragm Stop 10 Pressure Plate 11 Diaphragm 12 Diaphragm Gasket 13 Plug Gasket 14 Plug 15 Seat Ring 17 Nameplate 18 Knob

* *

* * *

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MODEL CA-2

Figure 1:

Basic Model CA-2 with

3-Connection Flow-Thru Body

ITEMS NOT SHOWN

16 Closing Cap 20 Closing Cap Gasket 21 Drive Screw

Option-5 Cryogenic Construction

Installed in horizontal line with spring chamber ori ent ed downwards below the body. Body and spring chamber Item Num bers are iden ti cal to Figure 1.

Option-22 Panel Mounting (handwheel portion is same

for Option-2 Handwheel)

Item No. Description

Repair Parts

Kit B

* * * * *

Cashco, Inc. P.O. Box 6 Ellsworth, KS 67439-0006 PH (785) 472-4461 Fax. # (785) 472-3539 www.cashco.com email: [email protected]

Printed in U.S.A. IOM-CA

Cashco GmbH Handwerkerstrasse 15 15366 Hoppegarten, Germany PH +49 3342 4243135 Fax. No. +49 3342 4243136 www.cashco.com Email: [email protected]

Cashco do Brasil, Ltda. Al.Venus, 340 Indaiatuba - Sao Paulo, Brazil PH +55 11 99677 7177 Fax. No. www.cashco.com Email: [email protected]